Precast edgeroll for helmet

ABSTRACT

An edgeroll for cushioning engagement of a helmet with the head of a wearer has parts prepared in ket form so as to be applied to the edge of a hard helmet shell in the field, throughout the entire perimeter of the exposed edge. A channelled part having a recess fitting the edge of the helmet has one leg longer than the other. One side edge of a cover sheet is fastened to the long leg by both adhesive and sewing. The sheet is reverse folded over the seam and around an insert of precast soft material, completely enveloping the insert and the free edge of the sheet extending beyond the insert is secured to the inside wall of the helmet adjacent to and spaced from the short leg of the channel part.

United States Patent 91 Bushman [111 3,806,949 51 Apr. 30, 1974 PRECAST EDGEROLL FOR HELMET [76] Inventor: Edwin F, Bushman, 123 E.

Montecito Ave., Sierra, Madre, Calif. 91024 22 Filed: June 23, 1972 [21] Appl. No.: 265,441

[52] US. Cl [51] Int. Cl A42b 3/00 [58] Field oi'Search 2/3 R, 3 A, 3 B, 3 C, 6, 2/274; 161/99, 100; l56/212,213, 93; 112/419; 264/47, 48, [56] References Cited UNITED STATES PATENTS 1,954,215 4/1934 Miller 156/93 2,604,664 7/1952 Jordan.... 264/48 2,700,183 1/1955 Beare 264/47 2,867,813 l/l959 Miller 2/6 3,200,448 8/1965 Brightm, 161/100 3,467,964 9/1969 Hannan 2/3 R Primary Examin rJames R. Boler Assistant Examiner-Wai M. Chan 57 ABSTRACT precast soft material, completely enveloping the insert and the free edgev of the sheet extendingbeyond the" 7 insert is secured to the inside wall of the helriietqglacent to and spaced from the short leg of the channel part.

9 Claims, 6 DrawingFigures 1 PREC 1ST EDGEROLL FUR HELMET Helmets used as flying gear need special construction so that they can be worn for long periods of time without fatigue, necessitating that they fit comfortably and closely not only over the crown of the head but also around the edges of the helmet shell itself. Since such helmets are customarily equipped with communication equipment systems, it is additionally necessary that they be so constructed as to exclude to the greatest degree possible extraneous noises which would otherwise interfere with the users hearing over the earphones. In view of the need for properly fitting comfort, many such helmets are custom made to suit the individuals head size and shape. Because the shape of the head varies to a considerable degree and since it is a practical impossibility to stock an adequate variety of head shapes as well as sizes, means needs to be provided to adjust the helmet shell, which may be of some standard size, to the shape of the head of a particular individual. Attempts, heretofore, to satisfy this requirement have involved the hand tailoring of a helmet edgeroll to suit individual needs. Although hand tailoring at the factory in the hands of skilled individuals is possible, such an expedient is not always feasible because any helmet which has to be selected in the field by field personnel and then sent to the factory for the hand tailoring of the edgeroll requires that the helmet be out of service for upwards of a month at a time.

On those occasions where hand tailoring has been attempted in the field, personnel are normally quite unskilled in such techniques. Additionally, equipment needed for molding and stitching of various parts of the edgeroll to the helmet is not always available. Even when equipment is available a good deal more time is needed for only partially or inadequately skilled personnel in the field to do a hand tailored job of fitting the edgeroll and results are often unsatisfactory.

It is therefore among the objects of the invention to provide a new and improved edgeroll kit which is partially preassembled at the factory with respect to the more difficult operations so that the final hand tailoring fit can be made in the field by relatively inexperienced personnel with the assurance of satisfactory results.

Another object of the invention is to provide a new and improved edgeroll kit significant portions of which are precast or otherwise preformed at the factory and partially assembled there and wherein the irregular parts of the edgeroll assembly are carefully formed to satisfy the ultimate need and at the same time prepared in such fashion that they can be quickly and easily snapped into place on the edge of a helmet shell where the assembly can be completed with a minimum operation and minimum expenditure of time.

Still another object of the invention is to provide a new and improved method for preparing, forming and applying an edgeroll assembly to the edge of a helmet shell wherein the more difficult and time consuming phases of the assembly can be performed at the factory, and in such fashion that the final phases can adequately be performed in the field where the helmet is to be actually fitted to the head of the user.

Also included among the objects of the invention is to provide a new and improved edgeroll assembly which is of such construction and design as to provide for uniform distribution of the weight of the device over the entire edge of the helmet shell and wherein by v 2 I providingamaiimumamountotcushiumuguddistibution of the same, especially in the area of the ears, good sound attenuation is achieved.

With these and other objects in view, the invention consists in the construction, arrangement, and combination of the various parts of the device, whereby the objects contemplated are attained, as hereinafter set forth, pointed out in the appended claims and illustrated in the accompanying drawings.

FIG. 1 is a perspective view showing a completed helmet mounted on a wearer.

FIG. 2 is a fragmentary cross-sectional view on the line 22 of FIG. 1.

FIG. 3 is a fragmentary cross-sectional view on the line 3 3 of FIG. 1. 7

FIG. 4 is a'fragmentary'perspective exploded view of partially assembled portions of the edgeroll.

FIG. 5 is a fragmentary cross-sectional view of another form of the invention.

FIG. 6 is a fragmentary cross-sectional viewof still another form of the invention.

In an embodiment of the invention chosen for illustration, there is shown a helmet 10 provided with an oxygen breathing mask 11 supplied by a hose 12 for use on the head 13 of a wearer. The helmet is adapted to engage the forehead 14 of the wearer, extending downwardly past the temples 15 thence around an area 16 beneath the ear and around and above the nape 17 of the neck. An attachment 18 is provided opposite the ear canal of the wearers head for engagement of an earphone (not shown).

An edgeroll assembly indicated generally by the reference character 20 extends around the perimeter of an edge 21 of the helmet shell passing across the forehead 14, temples 15, area 16 and nape 17. As indicated by the cross-sectional configuration of FIG. 2, that portion of the edgeroll assembly which accommodates the forehead is somewhat different in detail from that portion of the edgeroll assembly which accommodates that nape as shown in FIG. 3.

An edgeroll channel 22 is precast or preformed, depending upon whether it be made of a molded synthetic plastic resin or some metal such as aluminum. The shape'or configuration of the edgeroll channel is made such as to precisely fit the edge 21 of the helmet shell over its entire perimeter. In the embodiment chosen the edgeroll channel has a relatively long outside leg 23 and a relatively shorter inside leg 24. A precast insert 25 is formed to follow the perimeter. The insert is of soft, foamy consistency such, for example, as a polyurethane sponge. This is preferably precast to accommodate the compound curve, the shape and size of which is determined by the perimeter of the edge 21 of the helmet shell. The cross-sectional configuration of the molded insert 25 varies with respect to the position it will occupy when applied to the helmet shell. Notably that portion of the insert 25, as illustrated in FIG. 3, to accommodate the nape of the neck and portions covering the area 16 beneath the ears is appreciably greater in area and depth than that portion of the insert 25 which is to lie against the forehead 14. Additionally, the exterior of the nape portion is almost entirely rounded and is provided with a channel 26 to receive the edgeroll channel 22 so that there is an overlying lip 27 at the rear of the helmet shell. Conversely, that portion of the insert which is to engage the forehead 14 has a flat area 28 located entirely inside of the helmet shell.

Portions of the insert intermediate the nape portion and the forehead portion vary progressively from the shape of the forehead portion to the shape of the nape portion, there being provided appreciable thickness around and below the ears or the area 16. An object in the provision of the shape and size of the insert is to assure complete, well distributed contact throughout the entire perimeter of the edgeroll assembly with the wearers head so as to exclude extraneous sounds to the greatest degree possible.

In preassembly portions of the edgeroll assembly a sheet which may be of leather or a synthetic plastic resin material of leather-like properties and appearance has one edge 31 attached to the long outside leg 23 of the edgeroll channel. In the chosenembodiment a line of stitches 32 is employed whereby the edge 31 is fastened to the edgeroll channel. This operation is a factory operation, upon completion of which strips 33 may be trimmed off. It is also advisable to use an adhesive at the area 34 where an appreciable width of the edge 3 1 is applied against the outside leg of the edgeroll channel. In some instances adhesive and stitching of heat welding may be employed. Under some circumstances either the adhesive or heat welding may be employed alone or the stitching employed alone. Once the attachment has been accomplished in the manner described, the strip is turned so as to provide a roll back section 35 which overlies the stitching on the outside and then extends downwardly along that portion of the edge 31 which is in engagement with the outside leg of the edgeroll channel.

I The subassembly just described of sheet and edgeroll channel is then shipped into the field in company with the precast insert 25. When the edgeroll assembly is to be tailor fit to the helmet of an individual user, a mass of adhesive is initially painted on the edge 21 of the helmet and a quantity of adhesive may be applied to the interior of the-edgeroll channel. The edgeroll channel is then pushed into position over the edge 21 of the helmet shell with the sheet hanging downwardly substantially as shown in FIG. 4. Thereafter the exterior of the inside leg 24 of the edgeroll channel is painted with ad hesive, the adhesive also being applied over an adjacent portion 36 of the inside helmet shell surface. The insert may also have its flat area 28 painted with a comparable adhesive coat and the insert then fastened adhesively to the inside of the helmet shell adjacent the edge. It may also be found preferable to paint the exterior of the insert 25 with adhesive as well as to paint adhesive on that portion of the sheet 30 which will be applied around the exterior surface of the insert. The presence or absence of adhesive bond between freeform areas of sheet 30 and precast insert 25 determines relative firmness and comfort locally of the edgeroll assembly.

After this application of adhesive has been accomplished, which is the only means of attachment requiring application in the field, the sheet is then folded around the exterior rounded surface of the insert until a perimetrical strip 37 can be pressed into adhesive engagement with the inside surface of the helmet shell. This is preferably pressed snugly and tightly in the initial application so that the sheet 30 fits smoothly and evenly throughout the adjacent exterior surface of the insert 25 leaving no air pockets, following which the perimetrical strip 37 is pressed into engagement with the helmet shell. Inasmuch as the sheet 30 is precut so as to have sufficient width at the different areas to completely accommodate whatever thickness and perimeter may exist in the insert 25 at that point, the insert will then finally be entirely covered with a skin formed of the sheet and the sheet at the same time will be both a skin, controllably adhering to the insert, and also a fastening means adhering as it does to the inside wall of the helmet shell. When the adhesives are appropriately set the edgeroll assembly then mounted on and fastened to the helmet shell, is ready for use. Since the sizing configuration of the parts is initially established at the factory, such sizing can be depended upon and the operations of the subassembly requiring skill, and employment of the time saving equipment, becomes a factory operation. The subassembled parts thereafter, carefully formed, cut and fitted as described, can be finally assembled together in the field, in place on the edge of the helmet shell, thereby taking full advantage of skilled workmanship where that is needed, and making use of only moderate skill in the field for the final step, without sacrifice to the effectiveness of the assem- In the embodiment of the invention of FIG. 5 an edgeroll channel 38 may be formed so as to fit conformably over an existing thin plastic or rubber edge beading 39 on the edge of a helmet shell 21 A hooked end 42 provides a shoulder adapted to engage over an edge of the beading. A second shoulder 43 engages the beading on the inside of the helmet shell. This reduces, and in some cases eliminates, the need for cement in the area over which it fits.

A precast edgeroll insert 40 may be molded of a flexible self-skinning plastic or rubber foam material, with attractive and durable surface skin characteristics such as color, decoration, grain and toughness. In this embodiment an integrally cast skin 41 replaces the cover sheet 30, and no separate sewing or adhesive attachment of cover sheet to foam or channel is required.

A further embodiment of the invention shown in FIG. 6 features an edge roll channel 38 formed similar to the edge roll channel 38 of the FIG. 5 featuring a similar hooked end 42 and shoulder 43 which engage the beading 39. In this instance a precast edgeroll insert 40' is molded of a flexible self-skinning plastic-like material having an integrally cast skin 44. An extension 45 of the cast skin is folded back on itself at 46 thereby to double the thickness of the skin but avoiding having any foam material at that location.

The form of invention of FIGS. 5 and 6 have the special advantage of being able to be snapped into place and there held without assistance of an adhesive.

While the invention has herein been shown and described in what is conceived to be a practical and effective embodiment, it is recognized that departures may be made therefrom within the scope of the invention, which is not to be limited to the details herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices.

Having described this invention, what is claimed as new in support of Letters Patent is:

1. A composite edgeroll in combination with a helmet shell providing contact between a helmet shell and the head of a wearer wherein said helmet has an edge forming a compound curve throughout its perimeter with portions overlying the forehead, temples, nape and upper jaw area beneath the ears, said edgeroll comprising a relatively rigid edge channel fitted over said outside leg and an inside leg and exterior and interior surfaces, a molded insert of soft yieldable foam material having an attachment area and a cushioning area, and a cover sheet having an attachment between one edge of said cover sheet and the exterior surface of said outside leg of said channel, said sheet having a back fold over itself adjacent said one edge and being in engagement with only the cushioning area of said insert, the other edge of said sheet extending away from the inside leg of said channel and being attached to the inside surface of said shell at a location adjacent to and clear of the inside leg of said edge channel and at a location separate from said attachment area.

2. A composite edgeroll as in claim 1 wherein there is a thin edge beading of plastic-like material at the edge of the helmet shell and the edge channel fits conformably over said beading.

3. A composite edgeroll in combination with a helmet shell providing contact between a helmet shell and the head of a wearer wherein said helmet has an edge forming a compound curve throughout its perimeter with portions overlying the forehead, temples, nape and upper jaw area beneath the ears, said edgeroll comprising an edge channel fitted over said edge throughout the complete perimeter and having an outside leg and an inside leg, a molded insert of soft yieldable foam material having an attachment area and a cushioning area, and a cover sheet having an attachment between one edge of said cover sheet and said outside leg of said channel, said sheet having a back fold over itself adjacent said one edge and being in engagement with said insert, the other edge of said sheet being attached to the inside surface of said shell at a location adjacent the inside leg of said edge channel, said insert having a relatively thick portion adapted for engagement with the upper jaw areas, relatively thin portions adapted for engagement with the forehead and portions of intermediate thickness adapted for engagement with the nape.

4. A composite edgeroll as in claim 3 wherein the portion of intermediate thickness has a channel therein with side walls of the channel overlying both outside 5. A composite edgeroll as in claim 3 wherein the relatively thin portion has a flat surface in engagement with the inside leg intermediate the free edge of the shell and the attachment of the sheet to the inside surface of said shell.

6. A composite edgeroll as in claim 1 wherein there is an adhesive bond between the cushioning area of the insert and the cover sheet.

7. A composite edgeroll as in claim 1 wherein there is a heat seal bond between the attachment area of the insert and the cover sheet.

8. A method of forming and applying to the edge of a helmet shell throughout the entire perimeter a three part subassembly edgeroll comprising an edge channel, an insert, and a cover sheet wherein portions of said perimeter are adapted to engage the forehead, temples, nape and upper jaw area beneath the ears of a wearer, said method-comprisingforming a perimetrical recess in said edge channel between outside and inside legs to fit over the entire edge of the heT with a relatively thick portion adapted with the upper jaw area and relatively thinner por lo adapted for engagement with the temple and nape, and forming a relatively fiat attachment area and a relatively rounded cushioning area, securing one edge of said cover sheet to the exterior of the outside leg of the edge channel placing the edge of the helmet shell in the perimetrical recess, adhesively securing the attachment area of the insert to the helmet shell adjacent the edge, back-folding said sheet over said edge and over the cushioning area of said insert, extending the other edge of the cover sheet in a direction away from the edge channel, then anchoring said other edge of said cover sheet .to the inside surface of said shell adjacent the edge thereof and at a location clear of said edge channel.

9. The method of claim 8 including applying adhesive to the cushioning area of the insert and fastening said cover sheet to the insert with said adhesive.

* molding an insert 

1. A composite edgeroll in combination with a helmet shell providing contact between a helmet shell and the head of a wearer wherein said helmet has an edge forming a compound curve throughout its perimeter with portions overlying the forehead, temples, nape and upper jaw area beneath the ears, said edgeroll comprising a relatively rigid edge channel fitted over said edge throughout the complete perimeter and having an outside leg and an inside leg and exterior and interior surfaces, a molded insert of soft yieldable foam material having an attachment area and a cushioning area, and a cover sheet having an attachment between one edge of said cover sheet and the exterior surface of said outside leg of said channel, said sheet having a back fold over itself adjacent said one edge and being in engagement with only the cushioning area of said insert, the other edge of said sheet extending away from the inside leg of said channel and being attached to the inside surface of said shell at a location adjacent to and clear of the inside leg of said edge channel and at a location separate from said attachment area.
 2. A Composite edgeroll as in claim 1 wherein there is a thin edge beading of plastic-like material at the edge of the helmet shell and the edge channel fits conformably over said beading.
 3. A composite edgeroll in combination with a helmet shell providing contact between a helmet shell and the head of a wearer wherein said helmet has an edge forming a compound curve throughout its perimeter with portions overlying the forehead, temples, nape and upper jaw area beneath the ears, said edgeroll comprising an edge channel fitted over said edge throughout the complete perimeter and having an outside leg and an inside leg, a molded insert of soft yieldable foam material having an attachment area and a cushioning area, and a cover sheet having an attachment between one edge of said cover sheet and said outside leg of said channel, said sheet having a back fold over itself adjacent said one edge and being in engagement with said insert, the other edge of said sheet being attached to the inside surface of said shell at a location adjacent the inside leg of said edge channel, said insert having a relatively thick portion adapted for engagement with the upper jaw areas, relatively thin portions adapted for engagement with the forehead and portions of intermediate thickness adapted for engagement with the nape.
 4. A composite edgeroll as in claim 3 wherein the portion of intermediate thickness has a channel therein with side walls of the channel overlying both outside and inside legs of the edge channel.
 5. A composite edgeroll as in claim 3 wherein the relatively thin portion has a flat surface in engagement with the inside leg intermediate the free edge of the shell and the attachment of the sheet to the inside surface of said shell.
 6. A composite edgeroll as in claim 1 wherein there is an adhesive bond between the cushioning area of the insert and the cover sheet.
 7. A composite edgeroll as in claim 1 wherein there is a heat seal bond between the attachment area of the insert and the cover sheet.
 8. A method of forming and applying to the edge of a helmet shell throughout the entire perimeter a three part subassembly edgeroll comprising an edge channel, an insert, and a cover sheet wherein portions of said perimeter are adapted to engage the forehead, temples, nape and upper jaw area beneath the ears of a wearer, said method comprising forming a perimetrical recess in said edge channel between outside and inside legs to fit over the entire edge of the helmet, molding an insert with a relatively thick portion adapted for engagement with the upper jaw area and relatively thinner portions adapted for engagement with the temple and nape, and forming a relatively flat attachment area and a relatively rounded cushioning area, securing one edge of said cover sheet to the exterior of the outside leg of the edge channel placing the edge of the helmet shell in the perimetrical recess, adhesively securing the attachment area of the insert to the helmet shell adjacent the edge, back-folding said sheet over said edge and over the cushioning area of said insert, extending the other edge of the cover sheet in a direction away from the edge channel, then anchoring said other edge of said cover sheet to the inside surface of said shell adjacent the edge thereof and at a location clear of said edge channel.
 9. The method of claim 8 including applying adhesive to the cushioning area of the insert and fastening said cover sheet to the insert with said adhesive. 